Decorative fastener assembly

ABSTRACT

A decorative fastener assembly including a nut insert and a decorative cap. The cap includes a flatted portion sleeved over a flatted portion of the nut insert and further includes a flange portion proximate its open lower end. An O-ring seal is compressed between the flange of the cap and the circular enlargement of the nut insert to preclude the entry of moisture between the cap and the nut insert. A top end wall portion of the cap is welded to an annular weld projection on the top end of the nut insert in surrounding relation to the central bore of the nut insert. As the weld projection is melted to perform the welding operation, the cap moves further downwardly on the nut insert to further compress the O-ring seal between the cap flange and the circular enlargement of the nut insert. The cap flange portion proximate its open lower end is then crimped over a circular enlargement of the nut insert.

RELATED APPLICATION

This application is a division of U.S. patent application Ser. No. 10/329,884 filed on Dec. 26, 2002.

BACKGROUND OF THE INVENTION

This invention relates to decorative fastener assemblies and more particularly to a decorative fastener assembly of the type including a nut insert and a decorative cap fitted over the nut insert.

Decorative fastener assemblies of the nut insert and decorative cap type are in common usage especially in the automotive industry wherein they are used for holding a wheel on a motor vehicle while presenting an attractive decorative appearance. When using a decorative cap fitted over a nut insert, it is always necessary to insure that the decorative cap is not dislodged from the nut insert and to insure that contaminants do not enter into the space between the nut insert and the decorative cap. Welding, adhesives, and crimping have been utilized to secure the decorative cap to the nut insert and O-ring seals have been utilized to preclude the entry of contaminants into the space between the decorative cap and the nut insert. Each of the described securement techniques has disadvantages. The welding technique creates a corrosive site between the nut insert and the cap which when attacked by moisture may ultimately lead to weakening or failure of the bond. The relatively low tensile and shear strengths of the adhesive bond present a problem as well as difficulties encountered in masking the nut threads from adhesive during the adhesive application process. The crimping technique allows some movement of the cap when it is wrenched on the nut. Whereas the O-ring seal is effective in precluding the entry of moisture between the cap and the nut insert, the seal itself has no securement function.

SUMMARY OF THE INVENTION

This invention is directed to the provision of an improved decorative fastener assembly.

More specifically, this invention is directed to a decorative fastener assembly which may be inexpensively produced, in which the bond between the cap and the nut insert is effective even over sustained periods of use, and in which the entry of moisture between the cap and the insert is precluded.

The decorative fastener assembly of the invention is the type including a nut insert and a decorative cap, the nut insert including a flatted portion proximate a top end of the nut insert for wrenching, a load bearing portion proximate a bottom end of a nut insert, an external annular ridge intermediate the flatted portion and the load bearing portion, and a central bore including internal thread means for threadably engaging a bolt; the decorative cap including a flatted portion fitted over the flatted portion of the nut insert, a top end wall portion fitted over the top end of the nut insert, and a flange portion at an open bottom end of the cap proximate the external ridge of the nut insert.

According to one aspect of the invention, the cap is welded to the nut insert, and the flange portion is crimped around an outer cylindrical surface of the ridge and under a lower annular surface of the ridge. This arrangement allows the crimped flange to assist the weld in precluding dislodging of the cap from the nut insert.

According to a further feature of the invention, the fastener assembly further includes an O-ring seal positioned around the nut insert above the nut insert ridge between the cap flange the ridge. This arrangement allows the O-ring seal to function to preclude the upward entry of contaminants between the cap and the nut insert whereby to protect the integrity of the weld.

The invention further provides a method of fabricating a decorative fastener assembly. According to the invention methodology, a nut insert is formed including a flatted portion proximate a top end of the nut insert for wrenching, a load bearing portion proximate a bottom end of the nut insert, an external annular ridge intermediate the flatted portion and the load bearing portion, a central bore including internal thread means for threadably engaging a bolt, and a weld projection extending upwardly from the top end of the nut insert; a decorative cap is formed including a flatted portion sized for fitting over the flatted portion of the nut insert, a top end wall, and a flange portion at an open bottom end of the cap; the nut insert is inserted into the open bottom end of the cap to move the flatted portion of the nut insert into the flatted portion of the cap and seat the weld projection against the top end wall of the cap; the cap is welded to the nut insert at the interface of the top end wall of the cap and the weld projection while pressing the nut insert and cap together whereby to melt the weld projection and spread the material of the weld projection to diminish the overall height of the nut insert to allow the cap to move further downwardly on a nut insert; and the cap flange is crimped over the nut insert ridge. This methodology provides a simple and efficient means of manufacturing a decorative fastener assembly in which the cap is held to the nut insert both by welding and by crimping.

According to a further feature of the invention methodology, the methodology includes the further step of positioning an O-ring seal around the nut insert prior to inserting the nut insert into the open bottom end of the cap. In this arrangement, the O-ring seal is clamped between the nut insert ridge and the cap flange in response to insertion of a nut insert into the cap and the O-ring seal is further squeezed between the nut insert ridge and the cap flange in response to the further downward movement of the cap on the nut insert resulting from the welding of the cap to the nut insert.

Other applications of the present invention will become apparent to those skilled in the art when the following description of the best mode contemplated for practicing the invention is read in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

FIG. 1 is a perspective view of a decorative fastener assembly according to the invention;

FIG. 2 is an exploded view of the fastener assembly;

FIG. 3 is a top view of a cap utilized in the fastener assembly;

FIG. 4 is a top view of a nut insert utilized in the fastener assembly;

FIG. 5 is cross-sectional view of the fastener assembly;

FIGS. 6A-6F illustrate steps in the formation of the fastener assembly; and

FIGS. 7A-7C provide further details with respect to the steps involved in forming the fastener assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIGS. 1-5, the decorative fastener assembly 10 of the invention, broadly considered, includes a nut insert 12, a decorative cap 14, and an O-ring seal 16.

Nut insert 12 is formed of a suitable metallic material and includes a hexagonal flatted portion 12 a proximate a top end 12 b of the nut insert for wrenching, a conical load bearing portion 12 c proximate a bottom end 12 d of the nut insert for receipt in known manner in a conical opening 18 a in a motor vehicle wheel 18, an external annular ridge 12 e positioned intermediate the flatted portion 12 a and the load bearing portion 12 c, a cylindrical surface 12 f connecting the lower edge of ridge 12 e and the upper edge of conical load bearing surface 12 c, and a central bore 12 g extending from the top end of the nut insert to the bottom end of the nut insert and including internal threads 12 h for threadably engaging a bolt of the hub of the associated motor vehicle whereby to secure the wheel 18 to the hub. Ridge 12 e comprises a circular enlargement of the flatted portion 12 a and includes an upper annular surface 12 i, an outer cylindrical surface 12 j, and a lower annular surface 12 k. Nut insert 12 further includes an annular weld projection 12 l extending upwardly from the top end 12 b of the nut insert in surrounding relation to the central bore 12 g.

Decorative cap 14 is formed of a suitable metallic material and includes a hexagonal flatted portion 14 a sized to be fitted or sleeved over the hexagonal flatted portion 12 a of the nut insert, a top end wall 14 b, and a flange 14 c at an open bottom end of the cap. Top end wall 14 b includes a central dome portion 14 d and a flat annular surface 14 e in surrounding relation to the dome portion. Flange 14 c includes an upper inclined annular portion 14 f and a cylindrical skirt portion 14 g sized to be fitted around the cylindrical surface 12 j of the ridge 12 e of the nut insert.

O-ring seal 16 preferably is of circular cross-sectional configuration and is made of a suitable flexible resilient compressible material such as natural or synthetic rubber or, preferably, a silicone material.

The assembly of the decorative nut assembly of the invention is seen, step by step, in FIGS. 6A-6E with further detail shown in FIG. 7A-7C.

Specifically, a nut insert 12 is suitably formed (FIG. 6A); a cap 14 is suitably formed (FIG. 6B); an O-ring seal 16 is positioned over the flatted hex portion 12 a of the nut insert (FIG. 6C) in a position overlying ridge 12 e and with the material of the O-ring slightly stretched (for example 5%) to firmly grip the nut insert; the nut insert is inserted into the open bottom end of the cap (FIG. 6D) to move the flatted portion of the nut insert into the flatted portion of the cap and seat the weld projection 12 l against the flat annular portion 14 e of the top end wall of the cap while pushing the O-ring downwardly on the flatted portion of the nut insert and clamping the O-ring between upper annular surface 12 i of the nut insert ridge 12 e and the angled portion 14 f of the cap flange; the cap is welded to the nut insert at the interface of the top end wall 14 e of the cap and the weld projection 12 l (FIG. 6E) while pressing the nut insert and cap together whereby to melt the weld projection and spread the material of the weld projection to diminish the overall height of the nut insert to allow the cap to move further downwardly on the nut insert and further squeeze the O-ring seal between the cap flange portion 14 f and upper annular surface 12 i of the nut insert ridge 12 e; and the lower edge 14 h of the circular flange portion 14 g is crimped inwardly and under the lower annular surface 12 k of the annular ridge (FIG. 6F).

The welding step is performed as an electric resistance welding operation and may utilize a schematically shown annular electrode 20 which is pressed downwardly against the annular surface 14 e during the welding operation so that, as the annular welding projection 12 l is heated to a temperature that permits bonding, the material of the weld projection is melted and spreads over the general area of the top of the nut insert while downward pressure is maintained on the electrode 20 to insure that the cap moves downwardly on the nut insert by a distance equal to the difference between the original height of the weld projection 12 l and the final height of the spread material 22 resulting from the melting of the weld projection. For example, the weld projection may have an initial height of twenty thousandth of an inch and the spread material 22 resulting from the melting of the weld projection may have a height of five thousandth of an inch so that the net downward movement of the cap on the nut insert during the welding operation amounts to fifteen thousandth of an inch. This fifteen thousandth movement, as noted, and as seen by comparison of FIGS. 7A and 7B, results in the further compression of the O-ring seal 16 and the further compressive flow of the O-ring seal 16 to an extent such as to substantially fill the triangular annular void defined between the upper surface 12 i of the ridge 12 e and the inclined portion 14 f of flange 14 c.

The mechanical crimping of the lower edge 14 h of the cap under the annular ridge of the nut insert improves axial retention and may also act to further compress the O-ring seal so as to further fill the triangular annular void between the flange and the ridge. The filling of the triangular annular void between the cap flange and the nut insert ridge by the O-ring will be seen to have the effect of providing a seal throughout 360 degrees to preclude the entry of moisture or other contaminants into the space between the nut and the cap and specifically to preclude the entry of moisture or other contaminants into the weld area.

The decorative fastener assembly of the invention will be seen to provide many important advantages. Specifically, the combined action of the crimping of the flange of the cap over the nut insert ridge and the welding of the cap to the nut insert provides a positive retention of the cap on the nut insert even when subject to repeated installations and removals. Further, the combination of the O-ring seal and the weld allows the O-ring seal to preclude the ingress of moisture or other contaminants to the weld interface whereby to preclude corrosion or other degradation at the weld site even over sustained periods of robust use. Further, the large axial spacing between the site of the O-ring and the site of the weld further enhances the ability of the O-ring to preclude the ingress of moisture and other contaminants to the weld site. Further, the utilization of the relative downward movement of the cap on the nut insert during the welding operation to compress the O-ring simplifies the assembly procedure and insures maximum compression and maximum sealing effectiveness of the O-ring.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law. 

1. A decorative fastener assembly including a nut insert and a decorative cap, the nut insert including a flatted portion proximate a top end of the nut insert for wrenching, a load bearing portion proximate a bottom end of the nut insert, an external annular ridge positioned intermediate the flatted portion and the load bearing portion and defining an upper annular surface, an outer cylindrical surface, and a lower annular surface, and a central bore including internal thread means for threadably engaging a bolt; the decorative cap including a flatted portion fitted over the flatted portion of the nut insert, a top end wall portion fitted over the top end of the nut insert, and a flange portion at an open bottom end of the cap, characterized in that: the cap is welded to the nut insert; and the cap flange portion is crimped around the outer cylindrical surface of the ridge and under the lower annular surface of the ridge to fix the cap to the nut insert; whereby to assist the weld in precluding dislodging of the cap from the nut insert.
 2. A decorative fastener assembly according to claim 1 wherein the top end wall portion of the cap is welded to the top end of the nut insert.
 3. A decorative fastener assembly according to claim 2 wherein: the central bore extends from the top end of the nut insert to the bottom end of the nut insert and defines an annular surface at the top end of the nut insert in surrounding relation to the bore; and the top end wall portion of the cap is welded to the annular surface at the top end of the nut insert.
 4. A decorative fastener assembly according to claim 3 wherein: the top end wall of the cap has a central dome portion and a flat annular portion in surrounding relation to the dome portion; and the flat annular portion of the top end wall of the cap is welded to the annular surface at the top end of the nut insert.
 5. A decorative fastener assembly comprising a nut insert and a decorative cap, the nut insert having an elongated internally threaded body provided with a polygonal sidewall extending from a top end thereof toward a bottom end thereof; a cap having an annular side wall of substantially the same polygonal form as the side wall of said nut insert body; the cap having a top end wall and being open at a bottom end thereof; the cap being sleeved over the nut body with its sidewall surrounding the side wall of the nut body and with its top end wall overlying the top end of the nut body; the nut body having an annular enlargement adjacent to but spaced from the bottom end thereof, defining an upper annular surface, an outer cylindrical surface, and a lower annular surface; the cap having an axially outwardly flared flange portion at its open end crimped over the outer cylindrical surface of the enlargement and under the lower annular surface of the enlargement; and the cap being welded to said nut insert to assist the crimped flange of the cap in precluding dislodgement of the cap from said nut insert.
 6. A decorative fastener assembly according to claim 5 wherein: the cap is welded to the nut insert at an interface between the top end wall of the cap and the top end of the nut insert.
 7. A method of fabricating a decorative fastener assembly comprising: forming a nut insert including a flatted portion proximate a top end of the nut insert for wrenching, a load bearing portion proximate a bottom end of the nut insert, an external annular ridge intermediate the flatted portion and the load bearing portion, a central bore including internal thread means for threadably engaging a bolt, and a weld projection extending upwardly from the top end of the nut insert; forming a decorative cap including a flatted portion sized for fitting over the flatted portion of the nut insert, a top end wall, and a flange portion at an open bottom end of the cap; inserting the nut insert into the open bottom end of the cap to move the flatted portion of the nut insert into the flatted portion of the cap and seat the weld projection against the top end wall of the cap; welding the cap to the nut insert at the interface of the top end wall of the cap and the weld projection while pressing the nut insert and cap together whereby to melt the weld projection and spread the material of the weld projection to diminish the overall height of the nut insert to allow the cap to move further downwardly on the nut insert; and crimping the cap flange over the nut insert ridge.
 8. A method according to claim 7 wherein: the central bore extends from the top end of the nut insert to the bottom end of the nut insert and defines an annular surface at the top end of the nut insert in surrounding relation to the bore; the weld projection comprises an annular weld projection extending upwardly from the annular surface in surrounding relation to the bore; and the top end wall of the cap is welded to the annular weld projection.
 9. A method according to claim 8 wherein: the top end wall of the cap has a central dome portion and a flat annular portion in surrounding relation to the dome portion; and the flat annular portion of the top end wall of the cap is welded to the annular weld projection.
 10. A method according to claim 7 wherein the method comprises the further step of positioning an O-ring seal around the nut insert prior to inserting the nut insert into the open bottom end of the cap, the O-ring seal being clamped between the nut insert ridge and the cap flange in response to insertion of the nut insert into the cap and the O-ring seal being further squeezed between the nut insert ridge and the cap flange in response to the further downward movement of the cap on the nut insert resulting from the welding of the cap to the nut insert.
 11. A method of fabricating a decorative fastener assembly comprising: forming a nut insert including a flatted portion proximate a top end of the nut insert for wrenching, a load bearing portion proximate a bottom end of the nut insert, an external annular ridge intermediate the flatted portion and the load bearing portion, a central bore including internal thread means for threadably engaging a bolt, and a weld projection extending upwardly from the top end of the nut insert; forming a decorative cap including a flatted portion sized for fitting over the flatted portion of the nut insert, a top end wall, and a flange portion at an open bottom end of the cap; positioning an O-ring seal around the nut insert above the ridge; inserting the nut insert into the open bottom end of the cap to move the flatted portion of the nut insert into the flatted portion of the cap and seat the weld projection against the top end wall of the cap flange while clamping the O-ring seal between the cap flange portion and the nut insert ridge; and welding the cap to the nut insert at the interface of the top end wall of the cap and the weld projection while pressing the nut insert and cap together whereby to melt the weld projection and spread the material of the weld projection to diminish the overall height of the nut insert to allow the cap to move further downwardly on the nut insert and further squeeze the O-ring seal between the cap flange portion and the nut insert ridge.
 12. A method according to claim 11 wherein: the central bore extends from the top end of the nut insert to the bottom end of the nut insert and defines an annular surface at the top end of the nut insert in surrounding relation to the bore; the weld projection comprises an annular weld projection extending upwardly from the annular surface in surrounding relation to the bore; and the top end wall portion of the cap is welded to the annular weld projection.
 13. A method according to claim 12 wherein: the top end wall portion of the cap has a central dome portion and a flat annular portion in surrounding relation to the dome portion; and the flat annular portion of the top end wall of the cap is welded to the annular weld projection.
 14. A method according to claim 11 wherein the method includes the further step of crimping the cap flange over the nut insert ridge.
 15. A method of fabricating a decorative fastener assembly comprising: forming a nut insert including a flatted portion proximate a top end of the nut insert for wrenching, a load bearing portion proximate a bottom end of the nut insert, an external annular ridge intermediate the flatted portion and the load bearing portion, a central bore including internal thread means for threadably engaging a bolt, and a weld projection extending upwardly from the top end of the nut insert; forming a decorative cap including a flatted portion sized for fitting over the flatted portion of the nut insert, a top end wall, and a flange portion at an open bottom end of the cap; positioning an O-ring seal around the nut insert above the ridge; inserting the nut insert into the open bottom end of the cap to move the flatted portion of the nut insert into the flatted portion of the cap and seat the weld projection against the top end wall of the cap flange while clamping the O-ring seal between the cap flange portion and the nut insert ridge; welding the cap to the nut insert at the interface of the top end wall of the cap and the weld projection while pressing the nut insert and cap together whereby to melt the weld projection and spread the material of the weld projection to diminish the overall height of the nut insert to allow the cap to move further downwardly on the nut insert and further squeeze the O-ring seal between the cap flange portion and the nut insert ridge; and crimping the cap flange over the nut insert ridge.
 16. A method according to claim 15 wherein: the central bore extends from the top end of the nut insert to the bottom end of the nut insert and defines an annular surface at the top end of the nut insert in surrounding relation to the bore; the weld projection comprises an annular weld projection extending upwardly from the annular surface in surrounding relation to the bore; and the top end wall portion of the cap is welded to the annular weld projection.
 17. A method according to claim 16 wherein: the top end wall portion of the cap has a central dome portion and a flat annular portion in surrounding relation to the dome portion; and the flat annular portion of the top end wall of the cap is welded to the annular weld projection. 